JPH0322257B2 - - Google Patents

Description

[Detailed Description of the Invention] The present invention broadly relates to lead-acid storage batteries (hereinafter referred to as batteries),
More particularly, the present invention relates to an apparatus and method for casting straps on battery cell elements.

Up until now, lead-acid batteries have been paired with either one of the positive or negative plates, which are filled with an appropriate space and enclosed in a number of covered lead grid electrical insulators. It has been customary to have battery cell element assemblies consisting of electrical pairs of plates on each pair of lugs (hereinafter referred to as lugs), made up of electrical pairs by means of straps cast in lead or lead alloys.

Although various efforts have been made to cast such lag straps, they have suffered from various drawbacks, including inefficient slow operation or difficulty in controlling the casting conditions. Various problems have arisen, such as, for example, temperature control of the mold and proper optimal and efficient casting of molten lead.

Cooling of the molten lead is facilitated after the hot molten lead is poured into an unheated, relatively cool mold. Therefore, the timing of inserting the element lugs into the rapidly cooling molten lead is difficult, and even a momentary partial delay will affect casting quality. In order to overcome this timing problem, it has been proposed to heat the mold by passing a heated fluid through it or by electrically heating the mold to bring it to the same temperature as molten lead. However, such proposals require large molds, slow heating and cooling, and are ineffective, making accurate control difficult. While efforts have been made to preheat the mold externally, such as by gas flames or torches, these gas flows cause significant noise problems and heating is inefficient.

Additionally, many prior proposals for casting straps lack temperature control to ensure uniform bonding of the strap and lugs. Therefore, the situation was such that there were parts that were satisfactory and parts that were unsatisfactory. Such bonds tend to peel off during use and have an adverse effect on the electrical performance of the storage battery.

Lead/acid batteries are considered to be required to transport molten lead or lead alloys for various purposes in manufacturing. In earlier methods, pipes made of stainless steel or other metals were used to deliver molten lead, and these materials were kept molten by resistance heating.
This method is commonly used, for example, to transfer lead or lead alloys from lead pots to pouring ladles used to cast straps.

OBJECTS OF THE INVENTION It is an object of the present invention to have a method for more effectively joining the straps of a lead-acid battery cell element to the ears of a plate.

Another object is to provide an apparatus and method that can ensure optimal casting conditions in the mold and molten lead during casting. To elaborate on the more specific purpose of the above-mentioned method, the apparatus and method are capable of relatively accurate control of molds and molten lead on a continuous base;
There is no need to pour metal into the mold at dangerous times.

Another object of the present invention is to achieve a relatively uniform fusion bond as previously discussed.

The objects and effects of the present invention will be made clear by a detailed description of the apparatus and method described and shown by Sjamberg et al. with reference to the drawings. The details of the application are shown below.

It is not the intention to limit the invention to the specific form expressed, but on the contrary, the invention is intended to supersede any limitations with the structure incorporating the ideas and views of the invention.

The present invention is a combination of methods and apparatus such as those described by Sjamberg et al., and the application is shown here without limitation.

While the method and model of the present invention may be used in conjunction with any desired apparatus, the battery shown is of the specific type detailed by Klang et al.

The present invention can be found to be useful in casting lugs and straps of various types of batteries.

Generally speaking, the present invention employs a unique resistance heating type for the battery strap mold.
It means that you have found something that is easy to do.

The selection of unique conditions is a method of casting straps previously discussed to solve problems in the prior art. It is believed that the fusion bonding of straps and lugs of the present invention yields more satisfactory quality than all the less hazardous casting operations of the prior art.

FIG. 1 shows a complete battery containing lug straps and cell elements according to the invention. The illustrated battery 10 is of the general shape shown by Klang et al. The embodiment will be clarified herein, but the case 11 has a partition wall 12 on the inside, and each battery cell 1 is placed inside the partition.
Contains 4I and 14T. The illustrated battery 10 has six cells, including two cells 14T facing each other at the back and four cells 14I located in the middle.

14I, 14T included in cell element 20
Each battery cell is illustrated in FIG.
Figure 2 consists of a large number of positive and negative electrodes,
They are twisted and folded sheets 21
are isolated in separate locations. Each plate is formed with a lug 22 attached to its upper end, with the lugs 22 of the plates aligned in one direction of the element 20. Plate lugs 22 of opposite polarity are aligned on the opposite side of element 20. The plates of the illustrated battery cell element 20 have a height longer than a width, and are stacked in a row in a longitudinal direction transverse to the plane of each plate. Cell element is strip 2
3 of tape to hold the plates of each cell element 20 as a composite package during handling.

In order to electrically couple the plates of each cell element 20 of the same plate, each row of plate lugs 22 is connected to each other by cast lead straps. In this example, the rows of plate lugs 22 adjacent to the inner partitions are
It is connected by a strap 24I formed by a number of upright tabs or tombstones 25 arranged adjacent to two suitable apertures. The straps 24I are provided on two rows of element lugs in the middle cell 14I, and on the rows of element lugs in the end cell 14T adjacent to the partition 12. It is being As is known in the art, battery cell 14I,
The 14T elements are electrically connected in series through each aperture in the partitions 12 by appropriate intercell connections of adjacent tombstones 25.

On the other hand, a terminal post 26 is provided on the strap 24T in a first row of lugs of the cell 14T element located at the end. It will be appreciated that such a terminal post strap 24T can be integrally molded with the terminal post 26, or alternatively can be separately attached or cast onto the strap.
The terminal post strap 24T in the illustrated apparatus is cast with an upright tongue 28 as shown in FIG. 6, after which the terminal post can be cast.

Turning now to the remaining drawings, particularly FIGS. 3 and 4, there is shown an apparatus 30 that includes the casting system of the present invention. A set of battery cell elements 20 is continuously fed in a multi-station fashion by a single single feeding conveyor and an element feeding circular table 35. What is supplied is a cell element 20 carried on one of the circular stations for the intermediate cell 14I.
The upper casting strap 24I and the straps 24I and 24T on the cell element 20 carried on another circular station for the terminal battery cell 14T. The completed elements of the terminal cell 14T are then conveyed to the first take-off conveyor 36, and the completed elements of the intermediate cell 14I are conveyed to the second take-off conveyor.
The illustrated circular station 35 has twelve generally similar mold and element transport conveyors.
It is one tombstone strap 24I
and every third station 4 with a mold for casting a strap 24T to receive a terminal post.
0T or terminal cell element station and a pair of molds for casting the tombstone strap 24I on the battery cell element 20 carried at that station.
It has two consecutive stations 40I or intermediate cell element stations. It will be appreciated that the illustrated circular table 35 allows processes to be carried out simultaneously on 6 cells (2 cells + 4 cells) of lead-acid battery battery cell elements. That is, the circular table casts every third circular station 40T strap on the element for two terminal cells and two consecutive station 40I straps for the four intermediate battery cells 14T.

The circular table features a continuous indexing of the element feeding station and the mold through a series of precisely controlled operating stations for lag strap casting under optimal conditions and an effective continuous base. have. In the apparatus illustrated in FIG. 3, a circular table 35 is indexed successively through twelve operating stations, one rotary station 40 at a time.

It is structured under the following. (45
45L from A in detail) 1) To rotating station 40, supply conveyor 3
1) a loading station 45A for loading a pair of cell elements 20 from 1); 2) an alignment station 45B for precisely aligning the rows of supplied element lugs 22 at a rotating station 40; a lead pouring station 45C filled with molten lead; 4) a flux station 45D with flux for immersing the element lug 22; Cooling stations 45F, 45G, 45H, 45I to solidify 7) Elevator head up station 45J to extract elements from the mold after it is confirmed that the mold has cooled to the predetermined temperature 8) Terminal cell element station 40T first An element unloading station 4 takes out terminal cell elements having been strap-cast (24T, 24I) to the take-out conveyor 36.
5K 9) From intermediate cell element rotating station to second take-off conveyor 38, strap 24I
An intermediate cell element unloading station 45L takes out the cast intermediate cell elements.The empty rotary station 40 is indexed again to a loading station 45A to receive the next pair of cell elements 20 for repeating the casting cycle. It will be done.

The circular table 35, which is most clearly illustrated in FIG. 7, has a rotary table 50 mounted on a rotary indexer 51, and a reference plate 52 on a device base 54. The rotary table 50 is
It has a frame 55 that stands upright in the center, and a large number of rotating stations 4 are mounted on round tables provided on the outside of the frame 55.
Transport 0. Indexer 51 is of a well known type. That is, at the time of starting, the rotating station 40 and table 50 carried to the continuous operation station 45 can be selectively rotated. In the illustrated apparatus there are twelve equally spaced operating stations 45, so in this case the indexer 51 is indexed rotationally in 30 DEG increments between successive stations. An indexer 5 is used to detect the rotational position of the circular table 35.
1 has an output shaft 56 and an associated cam 58 which engages the appropriate limit switch.

Each rotating station 40 is generally similar and has a pair of battery cell elements 20 and an element holding head for being carried by the rotating station. It has a mold set under the elevator for casting lugs and straps simultaneously on two cell elements. The mold is then cooled with air injection tubes very close to the mold 61.

Additionally, a station control panel is provided on the upright rotating frame 55, and a separable control connection has the logical energizer of the rotating station 40 coupled to the main control of the device through the operating station. As indicated above, the mold cavity shapes are different, one for the terminal cell 14T and one for the intermediate cell 14I, respectively. The circular station is the end or intermediate cell 14T or 1
For casting straps on elements for 4I.

Each rotating station 40 on the rotating table
The air supply line 66 under the frame plate 52 is connected to a T-shaped air supply line 69 carried by the rotation of the table 50.
through a rotating union 68. The supply line 69 has one outlet for the parts through a pressure regulator to the mold cooling air supply manifold 71, which supplies each rotary station 40 with a respective cooling air and a solenoid-driven regulating valve SOL-
1 via line 74. The other outlet end of the T part of the air supply line 69 is connected to another T part 76.
are coupled to each other via a line 75. One of the other T-pieces is connected via a pressure regulator 78 to the elevator head clamp and solenoid SOL-3 valve for each rotating station 40.
Additionally, it connects lines 80 to the elevator head clamp air manifold 79 of each station.
are connected to each other via. T-shaped part 7
The other end of each rotary station elevator head 60 is connected to a SOL for controlling the raising and lowering of each rotating station elevator head 60.
A series of double starts, designated SOL-2a and SOL-2b, are connected via pressure regulators located on solenoid start valves. I will discuss this in detail later.

A slip ring assembly 86 is provided at the upper end of the frame of the circular table for coupling the main controller to the circular table 35 and for providing power to the circular table. A slip ring assembly 86 resides in a housing 87 mounted to the top of the rotating station 55 and includes bearings 88, 8 to enable proper rotational movement of the circular table.
It has a stator 86a supported by 9. Slip ring assembly 86 includes a number of current collectors 86b within housing 87, which are electrically coupled to each rotating station 40.

Each rotary station logic connector 65 is supported depending from the underside of the rotary table 50 to enable selective coupling of the individual rotary stations 40 to the machine's main control while located at the operating station, and , selectively coupled by respective operating station logic connectors 65a as shown in FIGS. 8-11. In fact, each rotary station logic pin 90 has a number of male logic pins 90, which are adapted to engage the same number of spring-biased female logic pins 90a carried in the operating station logic connector 65a. ing.

A rotating station 40 is attached to the operating station 45.
For selectively coupling the logic connectors 65, 65a during indexing, each operating station logic connector 65a is mounted in a bracket 91 and controlled for vertical movement by an upright guide rod 92 mounted on the frame plate 52. Therefore, it is supported.
The equipment bracket 91 has a flange 94 attached to the upright end of the air cylinder rod 95a on the actuator and also has a logic connector 65a in operational engagement with the rotary station connector 65 during startup. raise. To facilitate reliable coupling of the logic connectors, the rotary table logic connectors 65 are mounted in a plate 96 provided on the underside of the rotary table 50 for lateral floating movement. plate 96
is a tapered bushing 9 carried by the operating station logic bracket 91 for guiding the logic connector 65 into proper alignment on the floating plate 96.
9 to engage the tapered lower end positioning pin 98
It has a pair of limit switch 100
is attached to detect the upper and lower positions of the operating station logic connector 65a.

As will be appreciated, it will be appreciated that an operating station logic connector 65a can be provided at each operating station desiring rotary station control or alarm through the machine's main controller. In the illustrated apparatus, an operating station logic connector 65a is provided for each operating station 45, except for the four cooling stations 45F-45I.

According to the invention, the rotary station mold is:
Heating and cooling are performed relatively quickly and accurately. 12th
The illustrated mold 6 as shown in FIGS.
1I and 61T are each a pair of meandering shapes, and they are one of the cast lug straps.
It has four elongated sections 105 each defining one mold cavity 105a. Elongated part 105
are laterally arranged parallel to each other and are fully joined by arcuate end fittings 106 with raised ends.
The two outermost mold sections 105 terminate in a pair of terminal flanges 108 that extend outwardly around the circumference of the rotary table 50. As previously mentioned, the design of the mold cavity 105a depends on whether the straps are cast into elements for the end or intermediate battery cells 14I or 14T (FIG. 4).
The intermediate cell element rotating station 40I is
It has a mold 61 with a cavity designed to cast only tombstone straps 24I on the cell elements to be transported, while the terminal element rotation station 40T casts one tombstone strap 2 on each cell element.
4I and one terminal post strap 24T
It has a mold 61T having a cavity for casting.

Each mold 61I, 61T has an elongated cavity-containing portion 105a on an upright post 110 in the raised position. For horizontal expansion and contraction of mold section 105, the mold is mounted on posts 110 between elongated sections 105 and attached to snap springs 11.
1 (Figure 39). The terminal flange 108 of the mold is secured at the flange (FIG. 29) by headed bolts 112 set in two elongated opposing holes 112a. To allow rapid mold exchange, mold mounting posts 110 and bolts 112 are secured to the mold carrying plate 114, secured to the base by bolts 116, and supported by rotary table 50. Ru. Removal of the mold installation plate bolts 116 removes the mold 61 and the installation plate 1.
14 allows easy assembly replacement.

In the present invention, each mold is of lightweight construction and is compatible with rapid electrical resistance heating and preferably forced cooling in continuous casting. Mold 61 is preferably made of stainless steel having sufficient electrical resistance to provide the desired heating by the flow of electrical current. Type 303 (industrial standard) stainless steel is highly suitable for molding and has an electrical resistance of 73 micro-ohm-cm at 68〓 and 96 micro-ohm-cm at 720〓. Other stainless steels in the 300 and 400 series also have reasonable resistivities and are satisfactory for mold making. It is best to avoid casting with materials whose composition is close to magnetic materials. Induced currents or newly generated ones can be worse than expected. This results in uneven and unexpected heating.

As is well known, the material used for strap casting depends on the alloy and general material used for the battery plate grid. Lead or many lead alloys are used. In fact, other non-ferrous metals and other materials are
Cast according to the present invention by selecting the appropriate time and current to obtain the desired heating.

Regarding the shape (outer shape) of the elongated mold 61, it is preferable to set the shape of the mold so that the applied electrical resistance heating can be performed quickly and effectively with minimum heat loss. Additionally, it is preferred to shape the cavity containing portion 105 so that a relatively uniform melt bond is achieved and the casting strap is cooled quickly and effectively. Therefore, the corners of the mold, as well as other areas remote from the cavity, including section 105, may be somewhat thicker than what is referred to as the working area of the mold, thereby allowing the electrical resistance heating of the mold to The heat generated is directed primarily to the strap being cast. The walls of the mold close to the cavity, including the thickened section 105, should be made as thin as possible to increase heating and cooling. Generally, this provides a relatively uniform mold cross-sectional area. Satisfactory fusion bonding properties of the straps and lugs are easily determined by microscopic examination of the fusion bond. Special conditions, such as areas with high temperatures, can be solved by making the mold thicker in those areas. Similarly, low temperature areas can be addressed by appropriately thinning the mold in those areas. That is, the use of strap electrical resistance heating provides a method of casting straps that is fast with minimal heat loss and allows for relatively precise temperature control. The resulting fusion bond can be of high quality even in standards that require completely uniform bonding.
From a turntable 52 for the purpose of mold heating,
Electrical contact clamps 120, shown in FIGS. 16 and 17, for selective connection of terminal mold flange 108 to a remote power source are provided at selected locations of operating station 45 where mold heating is required. Upon indexing the rotary station to such an operating station, the clamp 120 may extend outwardly and engage the terminal flange 108. Each operating station clamp 120 has a pair of contact clamps 121 located at the upper end of a respective upright support bar 122 supported by the frame plate 52 at the operating station. As shown in FIG. 17, each clamp head 121 has a lower spaced flange 121b supporting a mold flange contact jaw 121a and one for actuating a springback air cylinder 124. As shown in FIG. During start-up of the cylinder 124, the mold flange 108 is inserted between the clamp jaw 121a and the flange 121 such that it is engaged between the end of the clamp jaw 121a and the cylinder rod 124a.
It has a cylinder rod 124a extending into the space between b.

In this case, the clamps 120 each have a mechanism that floats within the clamp during rotational indexing onto a support rod 122 to facilitate positioning of the mold flange.
Therefore, the clamp head 121 is attached to the support rod 122.
A spring 125 inserted between the upper side of the bracket 126 provided on each of the upper support rods 126 and the lower side of the clamp head 122
2 for relative movement. With the air cylinder 124 in the retracted or unclamped condition as shown in FIG. can be easily moved into the clamp. With mold flange 108 in such a position, actuation of cylinder 124 will tend to move cylinder rod 124a into engagement on the underside of flange 108, causing rod 124a to move into engagement with the underside of flange 108. The extension pulls the clamp heads downwardly onto their support rods against the deflection force of spring 125. When the rotary station is indexed again, the springback cylinder 124 is unloaded to retract the rod 124a. Accordingly, the clamp head can be returned to the raised and open position. The head 121 of the electrical contact clamp 120 is coupled to a suitable power source at the operating station where the clamp is located and where mold heating is required. The mold 61 is preferably heated during continuous operation of the operating station by passing the required electrical current through the contact clamp 120 to the mold and brought to the appropriate heating temperature before pouring the lead. The temperature should be above the melting temperature of the molten lead introduced into the mold, and be sufficiently high to activate the flux conditions applied to the previously cast element lugs; During bonding, the temperature is below that at which some of the element lugs may be substantially melted. It has been found that in that way the temperature of the working part of the mold can be satisfactorily maintained at the temperature of the lead or other material being cast. As will be appreciated, very large differences between the material being cast and the mold temperature will result in an unsatisfactory joint due to rapid solidification, for example, below the required casting temperature of the strap section or equivalent section. In the illustrated embodiment, it has been satisfactory to maintain the temperature of the active portion of the mold at least 720 ± 50, and more preferably 720 ± 30. It is believed to be important that the temperature of the molten strap material in which the lug is immersed is maintained at a relatively uniform and desired temperature for fusing with the lug. The necessary fusion bonding does not require that the majority of the lug be in molten condition. However, in practice it has been found that the tips of the lugs sometimes melt a little during casting. This does not reduce the quality of the fusion bonding result.

In the illustrated embodiment, the electrical contact clamp 12
0 is unloading station 45L for intermediate cell element, loading station 4
5A, alignment station 45B, lead pouring station 45C, and fill the two molds first,
It is located in a continuous casting station and is located in a flux station 45D that allows heating of the mold. This can be judged correctly from the following points. Since the mold heating current is supplied from many different operating stations separate from the rotary table, the appropriate current is supplied to the slip ring integrally 86.
By passing the heating current directly to the rotating station through the
A number of rotary station molds are provided for heating simultaneously. Depending on the mold structure, heating method, and mold heating capabilities in continuous stations, the desired preheating conditions can be achieved with relatively precise control.
Can hold molds for each table station.

Each mold 61 at various rotating stations 40
A thermocouple is placed in each mold to monitor the temperature of the mold, and the thermocouple is connected to a temperature controller 131 at each rotary station having two points: low and high temperatures. The high temperature setting is
A temperature at or slightly below the desired preheating temperature of the mold is desirable, and the cold side is preferably set at the desired mold temperature after sufficient cooling to permit undamaged removal of the casting. For the most accurate temperature monitoring, a thermocouple 130 is connected to the mold body in the center along the elongated mold section 105 and extends into the mold at a point very close to the cavity wall. A typical thermal sequence for the preheating station described above is as follows. Each station has a voltage of 11V and an initial current of 750A.
It is heated for 2 seconds. This is approximately 50〓/sec.
to raise the temperature. In continuous operation, the typical mold temperature at the beginning of each cycle of operation is initially approximately 200 to 250 degrees, so the desired high temperature set point is the third heating during the heating step.
Alternatively, this can be accomplished periodically at the alignment station such that the temperature controller detects a drop in temperature below the high temperature set point and the master controller cuts current to the station until the current is restored. At every interruption in the operating cycle, the preheat station continues the ON-OFF heating cycle to maintain the mold temperature at the resulting set point.
The mold is heated with a lead pouring station and a flux station to maintain the desired temperature by supplying 6V voltage and 400A current. Heating at the flux station lasts 4 1/2 seconds, while heating at the lead pouring station is limited to the time remaining after completion of the lead pouring step, which lasts approximately 1/2 to 1 second. It is. During interruptions in the operating cycle,
Heating of these stations continues in the same way as for the preheating stations described above. Clamp 120 for electrical current through the mold during heating
and the mold 61 is isolated from the part of the device that supports it. In this case, the clamp head 121 is attached to the plastic sleeve 132 (first
6 and 17), the plastic cap 134 is mounted on the clamping cylinder rod 124.
a and supported at the end of the cylinder rod 124
a and the cylinder 124 are the sleeve and plate 1
35, the lower clamp head flange 1
21b. The mold support posts 110 also each have a sleeve 136 (39th
The suitably spaced sleeve and spacer are separated from the plate 114 by spacers 138, 139 (FIG.) and have spacers 138, 139.
From Figure 7, the mold flange 108 and bolts 112 are separated. Referring specifically to the loading station of the apparatus illustrated in FIGS. 3 and 12, the transport conveyor conveys the cell elements 20 in a regular upright configuration with upwardly facing lugs 22 to a pick-up position at the end of the conveyor. The transport mechanism 140 grips and inverts a pair of elements 20 and transports them in an inverted state to an element holding elevator head 60 of a rotating station. The transport conveyor 31, best seen in FIGS. 12 and 13, is a set of unique driven conveyor belts 141 adapted to move two laterally spaced rows of elements 20 in the direction of the transport mechanism. has. The conveyor belts 141 are driven from a drive motor 142 via independent drive motors 142, each belt being connected to a chain 144 driven by the drive motor 142 and to a bearing block 146 supported from the underside of the conveyor frame 148. and a supported belt drive shaft 145. element 2
Each upper horizontal portion of the conveyor belt 141 on which the 0 rests is supported by a suitable belt guide. Since the elements 20 are arranged in a regular upright manner on the belt 141, they are easily conveyed by the conveyor with the guide block 150 provided near the upper position of the elements.

A pair of movable stop pins are provided at the ends of each belt 141 to stop the pair of moving elements 20 in a pick-up position near the end of the conveyor 31. Stop pins 151a are attached to each air cylinder 1 which is laterally supported by conveyor frame 148 (FIG. 13).
51. When the pair of elements reaches the stop pin to be prepared for pickup by the transport mechanism 140 (FIG. 14), the cylinder 151 is moved because the pin 151a is pulled. During removal of the element by the transport mechanism, each photocell 152
As shown in FIGS. 3 and 15, light is detected from the paired reflectors 152a, and the phototube is activated to return the stop pin to its extended position or to the element stop position. give a signal.

Loading station transport mechanism 14
0 is the 12th, 14th, 15th and 18th to 21st
A support bracket 15 extends outwardly from the frame plate 52, as best shown in the figure.
6 has an extendable, pivotable transport arm 155 mounted on it. The support bracket 156 in this case has a lower upright support channel 156a and an upper yoke 156a that is selectively positionable above the channel 156a. Yoke 156b is secured by bolts 158 at selected positions for the desired elevation of transfer arm 155. The transport arm 155 has a set of elongated guide rods 157 with the outermost clamping head 158 adapted to the gripped elements at the end of the take-off of the transport conveyor. Clamping head 158
has a pair of U-shaped clamps 160 mounted on the shaft carried between the flanges of a crossbar bracket 162 attached to the end of the guide rod 152 for proper conveying sliding action. Each of the clamping portions 160 has an inner leg 160b positioned in close proximity, and the outer leg 160b supports a clamp bar 164 that is laterally movable, thus allowing the inner leg 16
0a and the outer element engaging station facing it, the double activation air cylinder is
To the rear of each clamp portion 160 is inserted between the extended flanges. Toward the element engagement position, each support leg 160
To move the relatively inner clamp bar to b, the single actuation cylinder 166 moves the clamp leg 16
on the outside of each clamp leg 160b, with a cylinder rod extending through each clamp bar 164 that supports 0b. Each clamp bar 164 is operated by a spring on the shaft coupled to the clamp bar.
They are released or offset to the released position of the elements and extend outwardly through the clamp legs 160b. Activation of the clamping cylinders 165 and 166 therefore consists in moving the leg 160a and the clamp bar 164 from the element receiving position shown in FIG. 14 to the element engaging position shown in FIG.
64 and leg 160a. Release of the clamp bar cylinder 166 and rearward movement of the clamp member cylinder 165 causes the clamp member of the transfer arm head 158 to return again by releasing, receiving, or releasing the element. In order to extend and retract the transfer arm 155, the transfer arm guide rod 157 allows for relative movement in the pivot bracket supporting the outwardly extending pair of pivotable support shafts provided in the support bracket yoke 156b. Therefore, it is provided. The pivot bracket 170 has at its center a double actuating air cylinder 172 having a cylinder rod 172a attached to the crossbar 162 of the transfer arm head 158. The function of the air cylinder is the distribution conveyor 3
14, and then into the retracted position as shown in FIG. 15. It will be returned. Magnetic switch 174, 175
is provided on the support yoke 156b in order to detect the retracted position of the transfer arm head 158 on the rotating station side of each transfer conveyor and transfer mechanism. Concentrating photodetectors 180 and 181 are provided on the sides of each rotating station and the distribution conveyor of the transport mechanism in order to detect the expanded state of the transport arm 155. The clamping head 158 is on the rotating station side of the transport mechanism for rotating the transport arm from a position adjacent to the clamping head on the conveyor side of the transport mechanism. One of the rotating bracket support shafts 171 supports a pinion 175, each of which can be rotated by a rotational movement provided in the yoke 156b of the support bracket. air/oil 2
The illustrated rotating body 179, known as an articulated type, includes a pair of air cylinders disposed on opposite sides of the swing bracket shaft 171 and opposed driven piston racks 179b engaging pinions 178. Each cylinder 179a has a . The above is shown in Figure 1.
4 and 21a-21e. By supplying air to the upper end of one cylinder 179a, the cylinder rack 179b is actuated downward with a force on the rack of the adjacent cylinder upwards, thus driving pinion 178.
rotates, and the swing bracket 170 and transfer arm 1
55 is displayed. The action of the opposing cylinders 179a of the rotation actuator rotates the pinion 178 and the transport arm 155 in opposing directions. The continuous operation of the transport mechanism transport station is
1a to 22a. The function of the cylinder 172 is to position the clamping head 158 at the end of the supply conveyor 31 to receive a pair of elements in their upright position.
The purpose is to extend the transport arm to move the . Further, the transfer arm head 158 is operated by the transfer arm and the cylinders 165 and 166.
Engage or connect elements. The head then retracts under the action of the cylinder 172 and is therefore able to retract or transfer the element from the transport conveyor (Fig. 21b).The transport arm, in its inverted position (Fig. 21c), The element is rotated by the action of a rotary actuator to place the element on the rotating station side. The transfer arm is moved again to the elevator head 6.
0 is expanded to grip the aforementioned element and to move the element and clamping head 158 which is carried to the rotating station. It will be described in detail later (Figure 21b). The transfer arm head 158 then releases the element and retracts leaving the element on the rotating station.

Each rotary station elevator head 60 shown in FIGS. 12 and 16 is mounted on an upright support shaft in a raised position above the rotary table 50 to receive elements from the transport mechanism. The elements provided and received by the rotating station are indexed continuously via the operating station. An elevator head support shaft 185 extends through the rotary table between the elongated sections of the mold. These are supported by bearings attached to the underside of the rotary table base 115 in order to cause appropriate sliding motion. The lowermost end of the support shaft 185 depends from the underside of the base 115 and is attached by a tie plate 188 to the end of a piston rod 189a of a fixed twin cylinder 189. The elevator head 60 of each rotating station in this case has a central leg 190.
and legs 190a provided on the outside of each, which define a pair of receiving grooves 190b.
An upright back plate 191 is provided on the head 60 behind each element receiving groove for placement behind the positioned elements 20. A clamping bar 192, which is laterally movable for selectively engaging an element positioned within the elevator head 60, is provided on the inside of each outer leg 190a.
Each clamping bar 192 has a series of cylinders 1 fixed to the outside of each leg 190a.
The cylinder 19 is supported on the end of the rod 94.
4, the clamping bar 192 is moved inward to the element clamping position (FIG. 20). Each clamp bar 192 is displaced outwardly or in a release direction by a central clamp bar shaft 196 extending outwardly through a support leg 190a and a cooperating spring. Elevator head clamp cylinder 19
4, the clamp cylinder 194 is connected to an air manifold 79 of the rotating station, and the clamp cylinder 194 is connected to an air manifold 79 of the rotating station.
9 is line 8 with each solenoid and control valve SOL-3 of the rotating station.
connected by 0.

Thus, when the clamp bar 192 of the rotary station elevator head 60 is in the released or element receiving position, the clamping head 158 of the transfer arm 155 is in the first position.
8. A pair of elements in the elevator head 60 are moved into a rotating station to a position immediately above and adjacent to the elevator head 60 as shown in FIG. position. With the element in position, the clamp bar 192 is actuated while the transfer arm head 158 releases the element and is moved from the rotation station to the retracted position as shown in FIG.

The transfer station logic connector 65a is configured to control a master controller 85 incorporated into the machine, as is apparent upon indexing the rotary station 40 to the loading station 45A and prior to the transfer of elements to the rotary station elevator head 60. The rotary station logic connector may be engaged with a rotary station logic connector that couples to the rotary station.
The electrical contact clamp 120 of the transfer station 45A is then combined with the flange 108 at the end of the rotary station mold 61 to preheat the mold. Following element loading of the rotary station, electrical contact clamp 120 and logic connector 65a are released from the rotary station in the manner described above, freeing the rotary station from electrical contact clamp 120 and logic connector 65a.
can be advanced to a rotation station and a mating alignment station 45B.

The alignment station shown in FIGS. 22-25 includes a lug alignment mechanism 200 having a lug alignment head 201 mounted on a reciprocating carriage 202 from a rotating station 40. The lug alignment head 201 is attached to a frame 204 having a rear portion supported from the underside of the carriage 202.
and two independent extensions projecting toward the front of the carriage. The frame extensions 204a each have a pair of elongated lug seat plates 204b;
Each row of lugs of element 20 can be positioned thereon. The carriage 202 in this embodiment has a guide rod 205 supported on the underside within a linear bearing block 206 for proper movement in one direction. Bearing blocks 206 are mounted on separately supported brackets on the extended outside of the frame plate 52 of the device.

To selectively move the carriage 202 back and forth from the rotating station, a dual air cylinder 209 is supported by a support bracket 208 and is mounted in a rearward direction secured to a suspension bracket 210 mounted after the carriage 202. It has a facing piston rod 209a. When the cylinder 209 starts, the rod 209a contracts.
From the (contracted) position shown in Figure 24, move the carriage 2.
02 rotating station is moved to an advanced position with the lug alignment head 201 located below the elevator head 60 and the element 20 therein. Carriage support bracket 2
The limit switch 211 provided on 08 is
Front and rear carriage stop positions 212 and 214 for detecting the forward and backward positions of the carriage 202
It operates by. To raise the lug alignment head 201 from its position below the element 20, it
In the rotary station elevator head 60, the plate 20 set in close proximity to the lugs 22 of the supported element 20
4b is located at the front of the carriage 202 in the raised position. An alignment head 201 is mounted on a guide post 215 depending from the underside of the carriage for limited vertical movement relative to the carriage. To raise the lug alignment head 201 on the guide post 215, an air cylinder 216 is mounted on the carriage 202 with a downwardly extending piston rod 216a to engage the frame portion behind the alignment head 201. Activation of the air cylinder 216 moves the rod 216a upwardly, raising the head a distance established by an adjustable stop 218 located on the carriage directly above the head. A limit switch actuated by a flange 20 mounted at the rear of head 201 detects the raised head position.

By moving the lug alignment head 201 in the lower position, in the manner described above, when moved by the carriage 202 in the rotating station, they align tightly the elements 20 held in the rotating station. It can be seen that a wide space is provided for the lug 22 that is not covered. After positioning the lug alignment head 201 under the element, the alignment head 201 positions the cylinder 21 on the lug seat plate 204b very close to the element lug 22.
It is raised by the action of number 6. With the lug alignment head 201 in the raised position, the rotary station elevator head 60 is allowed to drop by releasing the supported elements and is supported on the lug seat plate 204b, thereby providing horizontal alignment of the lugs. enable. A plurality of pairs of guide rods 225 extending forwardly to hold the element in an upright position by the elevator head 60 upon its release are provided on a bracket 226, which in this case is attached to the upper end of the cylinder 216. Each pair of guide rods 225 has one
placed in close proximity on opposite sides of the two elements. It is formed with an outwardly flared forward end, which is also capable of guiding the rod into position around the element during movement with the alignment head into the rotating station. one of the air cylinders to provide a secure connection of each element to the plate 191 at the rear of each elevator head.
The pair is mounted on the carriage 202 and has a plunger rod 228a. The rod extends to apply a force to the element against the rear plate 191 upon activation of the cylinder 228.

The alignment head 201 is on the raised seat plate 204b.
An alignment head 201 for the elements of the rotating station supported thereon and appropriately related to the rear plate 191.
is applied to the clamp and precisely aligns the element lugs 22. In this way, each alignment head frame extension 204a has two clamp assemblies 230, 231 for lateral movement relative to the respective set plate 204b.
carry. The first clamp body 230 has a pair of supported shafts 230a that can slide within the alignment head frame 204a and have outwardly expanded ends brought together by an extended connecting bar 230b. are doing. Clamp 23
A pair of plates 204b and 0c are respectively set.
are mounted separately at opposite ends of the shaft adjacent to the inside of the shaft. Second clamp body 231
is the shaft 230a of the first clamp body 230
, supported by appropriate sliding motion, and
Includes a pair of clamps 231c provided, each set coupled by an extended 231a through the outermost of the two set plates 204b of frame extension 204a. It is arranged outside the plate 204b.

A double air cylinder 231b is used to control the movement of the mutually related alignment clamps 230 and 231 that affect clamping, and to align the element lugs positioned on the seat plate 204b.
is provided on the outermost clamp 231c of the second clamp body 231 and has a piston rod 231d that extends outward from the frame extension attached to the connecting bar 230b of the first clamp body 230. ing. Cylinder 231b
When applied to move rod 231d inwardly, clamp 230c, shaft 230a, and connecting bar 230b of instrument 230 are pulled inwardly, as shown in FIGS. 26 and 27. Meanwhile, clamp 2 of the second device 231
31c and cylinder 231b are actuated outwardly by the reaction force. Clamp 230 thereby moved relative to the released position.
c, 231c are the alignment head seat plates 204.
Allows unorganized element lugs to be moved from b and held in a rotating station that is positioned. Cylinder 23 in the opposite direction
1b, as shown in FIGS. 26a and 27b, the piston rod 231d expands outward toward the bar 230b of the first device and the shaft 2.
30a and clamp 230c, while the reaction force moves the clamping plate 231c, shaft 231a, and cylinder 231b of the second device 231 inward. Therefore, the seat board 204
The clamped element lug 22 is positioned at b and a sufficient force is applied in the longitudinal direction. Based on the above alignment, the rotating station elevator head 60 has the elements again:
Once grabbed, lug alignment head 201 releases the element, lug alignment head 201 lowers, and carriage 202 pulls alignment head 201 from the rotating station.

In the manner described above, the aligned lugs 22 are conveyed to the rotary station 35 and, with accurate lug alignment, are stably fed to the rotary table where, following lug alignment, the elements are It will be appreciated that the die is then held in the rising head at precise conditions throughout the casting operation. After the lug alignment operation is complete, the logic connectors and electrical contact clamps at the alignment station are separated from the rotating station, which can be indexed to lead pouring station 45c. As will be discussed in more detail below, prior to such indexing, the main controller determines whether the mold has been transported from a station heated to the high temperature setting of temperature controller 131. If not, the rotating station is parked at the alignment station until the mold reaches heating temperature. In indexing the rotary station to the lead pouring station 45c, the station's thermal control clamp 120 and the logic connector 6
5a are combined at a rotating station. Figure 2
8, 28a, and 29, the lead pouring station 45c includes a ladle 240 containing molten lead supported by a carriage 241.
, which is supported for sliding movement onto a rotating station on guide rod 242.
The guide rod 242 is mounted on a support bracket that extends outwardly from the frame plate 52. Movement of the ladle 240 from the retracted position is shown in FIG. 28 and further shown in the advanced position 28a, in which the dual air cylinder 245 is engaged with the upright plate 244a of the outwardly expanded support bracket 244. It is provided between the pot carriers 241. Limit switches 246, 248 provided on the support brackets allow the ladle 240 to advance,
Detect the position of each retreat.

The illustrated ladle 240 has four pour ports, with each mold 6 advanced to a lead pour station.
1 through each elongated portion 105 of the pouring spout,
It is applied to the simultaneous dispensing of controlled amounts of molten lead. In this case, the ladle 240 and the pouring spout 2
Each of 50 has an electrical heating element 251 to maintain the molten lead at a temperature above its melting point. Each pouring port 2 is used to control pouring of molten lead into the mold.
50 has a cascading vertically disposed valve rod 251. As seen in Figure 28,
Raising the valve rod 252 from the provided closed position results in a raised pouring condition as seen in Figure 28a. The valve rod is suspended from the underside of one of the ends of the pivot plate, and the other end is attached to the rod 255a of the air cylinder 255.
installed on. As a well-known technique,
Control of the amount of lead is distributed through each pour port by controlling the depth of molten lead in the stroke ladle of timing cylinder 255.
In this case, an adjustment stop 258 is provided on the rod extension 255b to limit the opening movement of the valve rod from each seat.

A weight 256 is mounted on a plate on the valve rod 252 to quickly and reliably close the valve following lead pouring. Following the lead pouring operation, the ladle is returned to the retracted position as seen in FIG. The figure shows the lead pour station thermal clamp 120 and the logic connector 65a released from the rotation station, and the rotation station indexed to the flux station 45D; , combined with a rotating station.

The flux station 45D shown in FIGS. 30-32 is designed for vertical motion with respect to the carriage in a manner similar to the previously described alignment head, and for forward motion of the rotary station in a linear manner with respect to the carriage. has a carriage 260 having a pair of plates mounted on it. The pan 261 is mounted on a pan support frame 262 suspended from the underside of the carriage. And each has a wet sponge 261a for the element lug, which can be cast of any material and has an appropriate flux to strengthen the molten lead bond. The carriage 260 has a guide rod 264 on the underside supported by a linear bearing block 265;
They are mounted on support brackets 266 extending from plate 52 attached to the machine.
Dual air cylinder 268 facing rearward
The support bracket 266 and the loading platform bracket 26
9, and through the action of the cylinder, the retraction of the rod displaces the carrier 260 from the retracted position. This retracted position is shown in FIG. 30, and the forward position shown in FIG.
0 is seen. The forward and backward positions of the carriage 260 are detected by limit switches actuated by front and rear bed positioning stops 271 and 272, respectively.

A flux plate 261 located below the element of the rotating station is raised by the action of a cylinder 274. In that way, plate 261
The moist spot flux within contacts each element lug. A flux plate support frame 262, similar to the alignment head of an alignment station, is suspended from below the carriage 260 defined by guide posts 275 and is secured to the rod end of the cylinder 274. A switch 273 is provided to detect the elevated position of the plate.

Following the fluxing process of the element lug 22, the flux pan 261 is retracted from the rotating station and returned to its lower position. and,
The rotating station is indexed to casting station 45E. As will be explained in more detail later, the machine's main controller 85 controls the release of the logic connector and the thermal control clamp from the rotary station, and only when the temperature is above a predetermined high temperature set point on the temperature controller 131. A rotating station is indexed to the casting station. If the mold bath is below such temperature, rotating station 60 remains at flux station 45D until the appropriate mold temperature is reached.

During the indexing of the rotary station to the casting station in the practice of the present invention, the rotary station elevator head can be lowered to immerse the element lug into the mold containing molten lead, and with a rapid response. The air cooling method is
It is operated to cool the mold and molten lead.
Other effective cooling methods for casting techniques are also known. Air cooling, as described above, has proven to be a relatively fast, effective, and reliable method of cooling. The molten strap material is cooled in this manner below its freezing temperature in about 30 seconds.
The materials used for the lugs and straps are such that the temperature of the strap to be cast is reached at the same time that the lugs are immersed therein, and the rate of cooling after immersion of the lugs is such that a satisfactory melting between the lugs and the straps occurs. Therefore, excessive dissolution of the lugs does not occur. The cast strap is then solidified and sufficiently cooled.
The cell elements so produced can be processed as desired without unfortunate fusion bonding in some critical areas between the lugs and the straps. Casting Station Logic Connector 65a to Rotating Station
In the apparatus shown following connection, the elevator head air cylinder 189 operates to expand the piston rod 189a. Then, the connecting bar 188, the guide rod 185, the elevator head 60 and the element 20 therein.
is pulled down. Furthermore, the element lug 20 is
It is lowered into the mold and dipped into molten lead to join the lugs. (Figs. 33 to 36) In order to operate the elevator cylinder 189, the air circuit 280 connects the two operating air control solenoid valves SOL-2a, SOL-2a, of each rotating station.
Connects SOL-2b and cylinder. It is controlled by the device's main controller, as detailed below. A proximity switch 283 is provided on the frame 53 and is connected to the elevator head 60.
is activated by reaching the lowest position. It sends a signal to the main controller that the head has descended.

Solenoid control valve SOL-2a, SOL-2
After the operation of b, the pressure switch 28 to the elevator cylinder 189 is activated to adjust the pressure of the air circuit.
1 (Figure 7). It is connected to the rotating station circuitry, the details of which will be discussed later. The cooling air control solenoid valve SOL-1 is actuated in accordance with the air discharged through the rotary station's air cooling pipe 62. In this case, the cooling piping 62 is located relatively close to each elongated portion 105, and the elongated air cooling piping 62 is installed below the elongated portion 105.
It has many of a. Specifically, a pair of cooling piping for the two elongated mold sections 105 of each element is placed in a slight gap between the corresponding mold sections; Air is ejected through exit holes designed to inject air outward and upward to a slight gap that touches the bottom surface. It is clear that the thin-walled suspended mold allows for relatively fast and uniform air cooling. In order to prevent spilled molten lead from accumulating around the air cooling pipe, the plate 114 on which the mold is mounted has a tapered part opened in the center, and the lead splashed at the tapered part falls downward. In order to incorporate the cooling air piping to the cooling air control solenoid valve SOL-1 of the rotary station, one set of cooling piping 62a on both sides of the mold is installed at the ends near the outer periphery of the rotary table 50, so that the cooling air piping is connected to the cooling air piping connected to the cooling air control solenoid valve SOL-1 of the rotary station. It is connected to a manifold block 62c. Each manifold block 62c is then incorporated into an air supply circuit 62d oriented in a T-shape 62e under the rotary table. It is also connected to control valve SOL-1.

Following the lowering of the elevator head in the operation of casting station 45E and cooling air,
The casting station logic connector 65a is released from the rotating station, thus allowing indexing of the rotating station into successive stations 45F, 45G, 45H and 45I. The flow of air through the cooling pipe 62a is effected solely under logical control of the operating station. That is, it requires no mold heating, no logic connectors, and no electrical contact clamps. There are also four cooling stations. The rotating station elevator head 60 is indexed through a continuous cooling station in the lowered casting position. The cooling air is then used until the mold is cooled to the predetermined low temperature setting value of the temperature controller 18I.
It is continuously injected through the cooling piping body 62. The low temperature of the cast strap will solidify and bond the element lugs, and the station's cooling air solenoid control valve SOL-1 will stop operating to shut off the cooling air.

When the rotating station reaches the elevator head up station 45J, the logic connector of that station 45J is disconnected. Once the mold temperature has cooled to the lower predetermined temperature set point, air supply is terminated. The elevator head cylinder 189 is shown in FIG.
The cast strap is removed from the mold and the elevator head 60 is actuated as shown in FIG. If the mold temperature has not decreased to the lower temperature setpoint after reaching the elevator up station 45J, the elevator head is parked in the lowered casting position until the mold has cooled to the lower temperature setpoint. Turn on the cooling air. elevator head 60
After the mold 61 rises, a phototube placed close to the mold 61 captures the light from the reflector. (Fig. 7, 38
(FIG. 39) The signal that the elevator head 60 has been raised enables the logic connector 65a to be released from the rotating station, and the rotating station
Indexed to terminal cell element unloading station 45K. The terminal cell element unloading station is illustrated in FIG. This is because it has an element transport mechanism 140a similar to the element transport mechanism of a loading station.

After indexing the terminal cell element station 40T to the terminal cell element unloading station 45K and after coupling the operating station logic connector 65a to the rotating station, the transport mechanism 140a is held at the rotating station elevator head in the opposite position. Push the transfer arm to grab the complete terminal element. The rotating station elevator head 60 then releases the element and the transfer arm returns, pivots, and extends to position the completed terminal cell element in an upright position on the released elevator.

On the other hand, the intermediate cell element rotating station is indexed via the terminal cell element unloading station 45K without moving the element. Intermediate cell element rotation station 4
0I intermediate cell element unloading station 45
After indexing to L, a transport mechanism 140 similar to the transport mechanism 140a for transporting the terminal cell element
b moves the completed intermediate cell element 24I and conveys it onto the intermediate cell element output conveyor 38 in an upright position. Specifically, the electrical contact clamp 120 connects the intermediate cell element unloading station 45L to the intermediate cell element unloading station 45L so that the mold can be gripped at the station to begin operating mold heating for the next casting cycle.
It is set in. After leaving the intermediate cell element unloading station 45L, the empty rotating station is indexed to the loading station 45A to receive the elements for repeating the cycle.

Control means are provided for coordinating each operation with a rotating station that performs successive casting operations on a continuous basis and under optimum casting conditions. As shown in the system diagram in Figure 40, the control method is as follows:
It has a main control unit consisting of conventional microprocessor-based programmable control equipment. That is Gould Modicon 484
It is a programmable controller and has its own programmed memory section and processor section that govern sequence operations. Details will be discussed later. Such master control is provided through a slip ring body 86 on the rotary station and through a logic connector 65 on the continuous operation station.
It is applied to transmit to each rotating station 40. The main controller directly conveys the control functions at the operating station 45. In each case, the main controller 85 performs the usual tasks of converting the output signals of the controllers to signal levels compatible with the equipment, and converting input signals from the equipment's various sensing devices to signal values compatible with the controllers. Conveyed through input/output signals. Furthermore, control means are further provided. It is also possible to select manual operation for the reliability of the device. If you pay attention to FIG. 41, you will see the electrical circuit diagram of each rotating station, which is the main controller 8.
Automatic operation of the device is possible under the control of 5.
Alternatively, manual operation of the rotating station can also be selected. In this case, circuit 295 connects logic pin LP1 of logic connector 65a at the operating station.
~LP6 and connected to the main control unit by sliding contact wheels SR1 to SR5. After movement of main coupling switch 296 to the "auto" position, switch contacts 298, 299 are closed while switch contacts 300, 301 are simultaneously opened. Closing of switch contact 298 causes current to be conducted between slip rings SR1 and SR2 to logic pins LP1-I shown at station "ON".
, a signal is given to the main controller and the station "G" light is turned on and transmitted. Its station is the intermediate cell element station 40I. For terminal cell element station 40T, signals are presented to the main controller through logic pins LP1-T.

The rotating station is loading station 45A.
Then, when the operating cycle begins, the main controller 85
is transmitted through logic pins LP3 and LP5.
As the logic pin rises to the upper position of the rotary station elevator head 60, the solenoid SOL
- 2a, the elevator head clamping bar 19 is conveyed forward and also for the position of opening them, releasing and receiving elements;
To the solenoid SOL-3 that enables the return of 2,
You can proceed. The element is loading station 4
At 5A, the programmed operation of the master control, positioned in the elevator head and communicated through logic pin LP5, activates the solenoid to clamp the elements of the elevator head.
SOL-3 is cut off. Through logic pin LP5, programmed signals from the master controller similarly open and close elevator head clamps at the alignment station.

At each rotary station, a temperature controller 131 is connected between slip rings SR3 and SR2 for various controls of operation in response to mold temperature, and temperature controller 131 is connected to a low temperature setting control. It has a low temperature setting that is connected to the TC-1a and is controlled in the normally open state, and also has a high temperature setting control that controls the TC-1a.
1b, is normally closed and has a controlled high temperature setting. As previously discussed, TC-1a, coupled by setting the temperature controller at the appropriate high and low set points, closes when the mold temperature is above the low temperature set point. The bonded TC-1b is then opened when the mold temperature is above the high temperature setting.

The rotating station is closed in high temperature control to operate the cycle quickly when the mold has previously been cooled below the low temperature set point, such as in loading station 45A. -1a, and the low temperature control is open and connects to Tc-1b. The closure of coupled Tc-1b sends a signal to master controller 85 through logic pin LP6 requesting heating in response. The main controller generates a force (electricity) to the electrical contact clamp 120 of the operating station, which is incorporated into the rotary station that heats the mold. When the mold heating temperature reaches the high temperature set point, the following occurs to a successive operating station that heats the mold. That is, the bond Tc-1b
is the electrical contact clamp 120 of the operating station.
is opened to provide a signal to the main controller through logic pin LP6. After indexing the rotary station to the casting station with the mold heated to the desired temperature, the main controller activates solenoid SOL-2b for the rotary station elevator head to lower into the casting position.
A signal is generated through logic pin LP4 to transmit the signal to the terminal. To lower the elevator head, the normally open pressure switch 281 is closed at the same time, and at the same time,
The already closed low-temperature coupling Tc-1a is connected in a circuit between slip rings SR1 and SR2, and air begins to flow to cool the mold. It is also detected by the main controller through logic pin LP2.

The cooling air control solenoid SOL-1 is connected between the rotation station slip rings SR1 and SR2, so that the cooling air is supplied to the rotation station through the cooling stations 45F to 45I connected by the main controller 85 without a logic connector. maintained as it progresses. The time during which the mold passes through the cooling station, after it has cooled to the cold set point, or at the elevator up station 4.
After reaching 5J, connection Tc-1a is opened, thereby cutting off solenoid SOL-1 and terminating the addition of cooling air.

When the rotating station is indexed to the elevator lift station 45J, it is coupled to the master controller through the indexing station's logic connector. The mold temperature is then below the low temperature set point and the open state of the low temperature bond Tc-1a is detected by the main controller through logic pin LP2.
Additionally, in response, master controller 85 issues a signal through logic pin LP3, thereby causing solenoid SOL to raise the elevator head.
-2a and remove the element from the mold. After the indexing of the rotary station to the dedicated unloading station, the main control transmitting through logic pin LP5 re-energizes the elevator head clamping solenoid SOL-3 in order to unload the element. tell.

During rotation station operation, each logic pin
LP3, 4 and 5 are inputs to the rotating station from the main controller for raising and lowering control of the clamping operation of the respective elevator heads, while logic pins LP1, 2 and 6 are inputs to the main controller. It is understood that there is. Moreover, circuit 29
5, it is possible to stop operation of the device either at the end of a cycle or in an emergency. As a result, between the slip rings SR1 and SR5, the coupled switch 310 causes the main controller to switch the main controller through the slip ring SR5 in response to the device causing an on-time completion of the current cycle. It can be closed manually to send a signal to the device. On the other hand, the temperature controller 131 continues the required heating and cooling. On the other hand, when the emergency stop switch 311 is manually operated, a signal is sent to the main control device through the slip ring SR4, and the couplings 313, 3
Close 14. In response, the operation of the rotary station and the operating station are immediately stopped, the high power output to the device is cut off, and the emergency stop light "R" is turned on.

Positive manual operation of the rotary station function moves switch 296 to the manual position, opening couplings 298 and 299 and opening couplings 300 and 3.
Close 01. Manual switch 315, 316, 3
17 and 318 are selectively actuated to actuate the cooling air, raise and lower the elevator head, and for elevator head clamp conditions, and to transmit signals to the respective control solenoids SOL1, 2a, 2b, and 3. be done.

As previously discussed, considering the programmed sequence of operation of the entire system 30 under control of the master controller, each of the operating stations has an individual power and air supply and transmission to the master controller 85. An operating station that is adapted to be able to operate and has a limit switch and a detection device. In response to such communication, the master controller is then adapted to perform the programmed functions sequentially in the detailed sequence and form.

After starting the two elements at the inlet station 45A in a regular upright position at the conveyed end of the supply conveyor 31, with the conveyor mechanism retracted and the stop pin extended, the conveyor side of the conveyor mechanism Clamping head 1
58 is opened or in a position to receive elements, and the transfer arm 155 is extended by action of cylinder 172 to move the clamping head into a position to receive elements on the supply conveyor. Therefore, the magnet switch 174 is opened and the phototube switch 181 is brought together.
(FIG. 14) The stop pin 151a is retracted by the action of the cylinder 151, and the transfer arm clamping head 158
5,166 grips the two elements on the supply conveyor. The transport arm 158 is retracted by the action of a cylinder that moves the elements caught in it from the supply conveyor. This activates the magnetic switch 174 and brings the phototube switches together. The phototube then detects movement of the element from the supply conveyor. And the stop pin 151a
is returned to the expanded position by the action of cylinder 151. The transfer arm 155, with the element in the inverted position, is vertically rotated 180 DEG by the action of the rotary actuator 179 to the position of the clamping head 158 on the rotary station side of the transfer mechanism. Then, magnet switch 1
74 is open and 175 is closed.

The release rotation station is the transfer station 45.
When indexed to a, the master controller influences the rotating station "station coupling sequence". It includes an electrical contact clamp 120 at the rotating station and a coupling logic circuit 65a. Then, by the temperature controller 131 which is transmitted to the main controller through the logic circuit (logic connector),
Preheat the mold to be determined. With the elevator head clamping bar 192 in the open or element-receiving position, the transfer arm 155 is extended to move the element into the elevator head inverted position.
This opens the magnetic switch 175,
Phototube switch 180 collects the light. Elevator head clamping bar 192 is cylinder 1
94 moves them into the element clamping position. Transfer arm clamping head 158 releases the element by rearward movement of cylinder 165 and deactivation of cylinder 166. The transfer arm then retracts, thereby leaving the retained element within the rotating station elevator head 60. Then, the magnet switch 175 is turned on, and the phototube switch 180 focuses the light. (Figure 20) The signal continues to be sent to the main controller, the loading station is ready for indexing, the main controller waits until all rotating stations are ready for indexing, and at the same time " Issue the station release sequence. This sequence has: Release force on electrical contact clamp 120, release thermal contact clamp, release logic connector 65a, wait until all operating station logic connectors are disconnected, and all operating station heads are removed from the rotating station. Inspect all the way to the retreated position. After completing the “station release sequence”,
The rotary stations are rotated 30 DEG by advancing the indexer of each rotary station to successive operating stations.

After indexing the rotary station to the alignment station 45R, the main controller again enters the "station coupling sequence" based on the above. The alignment head 201 is provided with a limit switch 211,
Elements carried into it and pulled into an expanded position under the elevator head (22nd
) from the loading platform 2 by the action of the cylinder 209.
Moved with 00. The alignment head is raised to the position of the set plate 204b by the action of the cylinder 216, and the alignment head is raised to the position of the set plate 204b.
b is in close proximity to the lug of the element supported by the elevator head 60 in which the limit switch 219 is provided. The elevator head clamping bar 192 is operated by returning the cylinder 166 to its original position after dropping the element onto the alignment head seat plate 204b.
Can be opened. The element positioning plunger rod 228a is expanded by the action of the cylinder 228 to firmly place the element against the reference plate 191 behind the elevator head.
Alignment head clamps 230c, 231c are moved into alignment and lug positions by the action of cylinder 231b (FIGS. 26a and 27a). Elevator head clamp 192 (20th
(Fig.) reconnects the elements by the action of cylinder 194. Alignment head clamp is cylinder 2
31b (Fig. 26a) releases the element lug. Element positioning plunger rod 228a is retracted by rearward movement of cylinder 216 (FIG. 25);
The alignment head 201 is then lowered by the rearward movement of the cylinder 216. Therefore, switch 219 is opened and, along with cargo platform 202, is retracted from the rotating station.
The limit switch 211 is then closed. The above is shown in FIG. The mold is temperature controller 13
After heating to a high temperature set point of 1 and sensing the temperature by the main controller through the logic connector, the alignment station “Ready to Index” will issue a signal followed by the same “Station Release Sequence” as described above. ”The rotating station is then indexed to the next station.

After the rotary station is indexed to the pouring station 45c, the main controller again enters the “station connection sequence” and the carriage 241
moves the ladle 240 from the retracted position (FIG. 28) to the pouring position (FIG. 28a). That is why switch 246 exists. Ladle valve rod 25
2 are raised to their open position by the action of cylinder 255 to allow molten lead to flow into the mold. In a defined sequence, the return of cylinders 255 to their original position returns them to the closed position. The ladle loading platform 241 is moved backward by the action of the cylinder 245. Hence the switch 248. The lead pouring station issues a "ready to index" signal and a "station release sequence" is executed. The rotating station is then indexed into successive stations.

Rotating station is flux station 4
After being indexed to 5D, a "station coupling sequence" is executed and the platform 260 is advanced from the retracted position (FIG. 30) to the extended position by the action of the cylinder 268. Therefore, there is a switch 270. Flux plate 261 located under the rotary station elevator head
The flux pan 261, together with the elements carried therein (FIGS. 30a and 31), is suitably lowered onto the platform 260 by the action of a cylinder for applying flux to the element lugs. Switch 273 is therefore opened. The loading platform 260 and the flux 261 are the cylinder 2.
68 is retracted, thereby opening switch 270. The mold is heated to the high temperature set point of the temperature controller 131 and the main controller 85 from the logic connections at the operating station.
After the detected temperature, the flux station issues a "Ready to Index" signal to the main controller followed by a "Station Release Sequence" in which the rotating station is indexed to the next operating station. Start.

After the rotary station has been indexed to the casting station 45E, the main controller again enters the "station joining sequence", this time at the casting station, there is no contact clamp joining heating and the elevator head 60 is connected to the molten lead placed in the mold. Cylinder 189 to immerse the element lug inside.
It is lowered by the action of Therefore, pressure switch 281 and proximity switch 283 (FIG. 7) are closed. After the switch 281 is closed, the cooling air control valve SOL-1 is opened to allow the cooling air to be blown through the pipe 67a on the mold, which is controlled by the temperature controller 131. detected and continued until requested. The “ready to index” signal of the casting station is issued,
Then the “station release sequence”
The rotating station is indexed to the first cooling station 45F with the elevator head lowered or remaining in the casting position.

The rotary station is indexed continuously through each of the four independent cooling stations 45E, 45G, 45H and 45I of the electrical contact clamps of the operating station or the logical connections of the main controller 85. After the mold temperature falls to the low temperature set point of temperature controller 131, cooling air solenoid valve SOL-1 is released to terminate cooling air injection.

After the rotary station is indexed to the elevator head up station 45J, a "station coupling sequence" occurs without another thermal contact coupling. If the mold has not been cooled to the cold set point control temperature before reaching this station, cooling continues until that temperature is reached. After the mold is detected at the cold set point, the elevator head 60 moves to the cylinder 189.
It is raised by the action of The position of the elevator head is detected by the light reflective sensor 258.
After being verified by , the elevator head up station is given a "ready to index" signal. Subsequently, there is a "station disjoint sequence" in which the rotating station is indexed to the next station.

After the terminal cell element rotating station is indexed to the terminal cell element take-off station 45K, there is a "station coupling sequence" without thermal clamp coupling. As previously indicated, at this station the terminal cell element transport mechanism 140a is coincident with the loading station transport mechanism and in reverse sequence to the mating completed terminal cell element of the rotating station elevator head 60. Be manipulated. The element is then moved from the elevator head to an inverted position, vertically rotated 180 degrees, and conveyed in an upright position onto the supply conveyor. The intermediate cell element rotation station 40I results in a terminal cell element take-off station 45.
It is moved forward to K. Then, the index is detected by the main controller through the logical connection,
The rotating station 40I is indexed through the terminal cell element take-off station without movement of the element. After the intermediate cell element rotation station has been indexed to the intermediate cell element take-off station 45L, the "station coupling sequence" is executed again. It also includes a mold heated thermal clamp connection. As previously mentioned, completed intermediate cell elements are similarly transferred from the rotary station elevator head on intermediate cell element supply conveyor 38 by reversing transport mechanism 140b. Rotating station 40 for terminal cell element
T is automatically indexed through this operating station. In other cases, the take-off station for the intermediate cell element signals a "prepare to index" and is in a "station uncombined sequence";
The rotating station is indexed to the loading station for repeating the cycle. As specifically described above, it is possible to judge the usefulness of the resistance heating type casting strap system of the mold according to the present invention. Specifically, the method includes heating the mold prior to pouring the strap material into the mold. This method allows the straps to be cast in a relatively short time, ensuring a fusion bond of satisfactory quality, and the temperature of such materials being at the desired casting temperature.
This avoids the practical danger of having to spend time casting the strap material until it can be easily held.

However, when using molten material dispensing equipment,
There is no risk in the required time to cast the strap. or where control of the amount of strap material is required to a extent that is not easily achievable. Such an application to strap casting is carried out by placing the desired amount of strap material into the mold, heating the mold by electrical resistance heating to the desired mold temperature, and melting the strap material. Immerse a portion of the lugs in the material and allow to cool to solidify the strap. In such embodiments, it is possible to provide the desired strap melt material from the lugs. More practically, the condition of the material added to the strap in the solidified state is more desirable. And then you will get the remainder from the molten material from the lug. The present invention, which allows strap casting regardless of the way the strap is made, provides a simpler method and more satisfactory quality of the fusion bond between the strap and the lug. Moreover, many problems of conventional casting techniques can be solved. Examples include the requirement for short timing of inserting lugs into cast strap material.

[Brief explanation of drawings]

FIG. 1 is a perspective view of a lead acid battery having cell elements of a cast strap made by the method of the present invention. FIG. 2 is an enlarged perspective view of one of the cell elements used in the battery shown in FIG. 1, prior to the casting straps on the lugs. FIG. 3 is a partial schematic plan view of an apparatus according to an embodiment of the invention. FIG. 4 is a plan view of the circular table and multiple station carrying the cell elements included in the apparatus shown in FIG. 3; There is a casting on the strap that is used as a battery cell at both ends and inside.
There is one element loading station and a separate unloading station.
FIG. 5 is a perspective view of the battery inner cell for casting straps with the apparatus shown. FIG. 6 is a perspective view of a battery end cell casting into a strap with the apparatus shown. FIG. 7 is a cross-sectional view of FIG. 3 taken along plane 7-7. Figure 8 shows
3 is an enlarged vertical cross-sectional view in plane 8-8, feeding the elements and molds of the rotary circular table in the operating position indicated by the point of descent shown in solid lines and the point of rise shown in phantom; Figure 2 shows the uncoupled logic state of the master controller incorporated in the device. FIG. 9 is a vertical sectional view of FIG. 8 taken along plane 9-9. FIG. 10 is a horizontal sectional view of FIG. 8 taken along the plane 10-10. Figure 11 shows Figures 8 to 10.
2 is an enlarged partial vertical cross-section view of one of the spring-loaded logic pins of the logic coupling seen in the figure; FIG. Figure 12 shows the third
FIG. 2 is an enlarged view of the element loading station of the device taken along plane 12-12 in the figure in a raised position. Figure 13 shows Figure 12 as 13-
13 is an enlarged vertical cross-sectional view of the element supply conveyor in the loading station taken along 13 planes; FIG. FIG. 14 is an enlarged horizontal cross-sectional view of the element transport mechanism of the loading station taken along plane 14--14 of FIG. 12, which is a transport arm that grabs and transports cell elements from above the supply conveyor. FIG. 15 is similar to FIG. 14 and is a plan view. It shows the element transport mechanism of the loading station which picks up the elements from the supply conveyor. 1st
FIG. 6 is an enlarged view of a vertical section taken along the plane 16-16 of FIG. 12. Figure 17 shows Figure 16 as 17-
17 is a vertical cross-sectional view taken through plane 17, showing the mold on a circular table being clamped in an electrical contact clamping station for heating the mold; FIG. FIG. 18 shows a side view of the lifting point of the loading station element transport mechanism of the transport arm positioning the cell elements onto the circular table. Figure 19 shows the 18th
19 is a plan view taken along the plane 19-19; FIG. 20th
The figure is a plan view taken along the plane 20-20 of figure 18, and this figure shows the loading station element transport mechanism in a lowered state after carrying the elements fed into the circular table. . Figures 21a-21e are sequential views of the operation of the element transport mechanism in the loading station. FIG. 22 shows an enlarged vertical cross-sectional view of the element alignment station of the device taken along plane 22--22 in FIG.
FIG. 23 is a view of the alignment device for the element lugs of the alignment station in the raised position in an operating position for aligning the lugs of cell elements carried by a circular table; Figure 24 is the same as Figure 22.
4-24 is an enlarged plan view of the lug alignment element device; FIG. FIG. 25 is an enlarged vertical cross-sectional view of the element lug alignment device taken along the plane 25-25 of FIG. 24. Figure 26, 26a
Figures 27 and 27a are two copies of each of Figures 24 and 27a.
It is a view cut along the 6-26 plane and the 27-27 plane. Figures 26 and 27 show the alignment clamp device in a position to accept unaligned element lugs, and Figures 26a and 27a show the alignment clamp device when the element lugs are checked and aligned. It shows. Figure 28 shows Figure 3 as 28-2.
FIG. 8 is an enlarged vertical cross-sectional view of the lead pouring station, cut in eight planes. Figure 28a is a vertical view similar to Figure 28, showing the ladle containing molten lead in the advanced position for pouring into the mold. 29th
The figure is an enlarged horizontal cross-sectional view taken along plane 29--29 of figure 28a, showing the position of the ladle being advanced and pouring lead. Figure 30 shows Figure 3.
Fig. 3 shows an enlarged vertical cross-sectional view of the flux station cut along the -30 plane. Figure 30a shows the 30th
This is a vertical cross-sectional view similar to that shown in the figure. However, this figure shows the flux tray being moved forward to bring it into contact with the lower part of the cell element that has been moved by the circular table. FIGS. 31 and 30 are enlarged plan views of the flux device taken along the plane 31--31. Figure 32 shows the figure 30a.
FIG. 3 is an enlarged vertical cross-sectional view taken along plane 32-32; FIG. 33 is an enlarged vertical cross-sectional view of the casting station taken along plane 33--33 of FIG. Third
FIG. 4 is an enlarged vertical cross-sectional view of FIG. 33 taken along plane 34-34. Figures 35 and 36 are local views of the immersion of the element lug into molten lead and the subsequent cooling operation in the casting operation. 37th
The figure is an enlarged horizontal sectional view of FIG. 33 taken along the plane 37-37. Figure 38 shows Figure 3 at 38-38.
FIG. 2 is an enlarged vertical cross-sectional view taken along a plane, showing the elevator head raising station for removing the cell element from the mold after the casting of the lag strap is completed. FIG. 39 is a partial view of FIG. 37 taken along plane 39-39. FIG. 40 is a control system diagram that includes a main circular station and a number of operating stations. FIG. 41 is an electrical circuit diagram of the main circular station. 14... Battery cell, 20... Cell element (cell element), 22... Lug, 24... Strap, 35... Circular table, 36... Conveyor, 40... Rotating station, 45A... Loading station, 45b ...Alignment station, 45c...Lead pouring station.

Claims (1)

[Scope of Claims] 1. A method of casting metal straps on lug rows of a plurality of battery cell elements, comprising electrically interconnected straps each formed of an electrically conductive material and having an elongated strap cavity. A mold body formed with a plurality of parallel sections is provided, and electrical current is passed continuously through the material of the mold cavity to heat the cavity to a predetermined temperature above the melting temperature of the metal to be cast. injecting a suitable amount of metal to form the strap into the cavity, immersing the array of element lugs in the cavity, and cooling the mold body to a temperature below the solidification temperature of the metal; A method for casting metal straps on the lugs of a plurality of battery cell elements, the method comprising: removing the plurality of element lugs from the cavity having the cast straps. 2. The mold body is heated to the predetermined temperature before the strap metal is injected into the cavity, and the strap metal is injected into the cavity in a molten state at the predetermined temperature. 2. The method of claim 1, wherein the lug is immersed in the cavity when the molten strap metal is at approximately the predetermined temperature. 3. The method of claim 1, wherein the strap metal is poured into the cavity in solid state and the mold body is then heated to the predetermined temperature. 4. The method of claim 1, wherein the predetermined temperature is approximately 720°C. 5. The method of claim 1, wherein said cooling includes air injection into said mold cavity. 6. The method of claim 1, further comprising monitoring the mold body temperature and passing the required current through the mold body intermittently to maintain the predetermined temperature. 7. A method as claimed in claim 1, characterized in that the lug is provided with a flux prior to immersion into the cavity. 8. In an electrically heatable mold for casting straps on respective rows of lugs, such as battery plates, a plurality of parallel elongated sections of electrically conductive material which receive the rows of lugs of the battery cell elements; a body having a cavity and a strap metal interconnecting the lugs of the row, the body being configured to provide electrical current conduction through the mold and a relatively uniform distribution of the elongated portion upon connection to a power source; An electrically heatable mold for casting a strap on each row of lugs, such as a battery plate, characterized in that it has electrical terminals that can be resistively heated. 9. An electrically heatable mold according to claim 8, characterized in that it includes means for collectively electrically coupling the ends of adjacent elongated sections. 10. The electrically heatable mold of claim 9, wherein the elongate portion and the coupling means define a continuous serpentine profile through which electrical current can be passed. 11. Claim 9, characterized in that said terminal means is one end of said two elongated portions.
Electrically heatable mold as described in Section 1. 12. The electrically heatable mold according to claim 11, wherein the two terminals are arranged on a common side of the mold. 13. The electrically heated device of claim 10, comprising a plurality of pairs of said elongate sections, each said elongate section having a mold cavity for a respective pair of rows or lugs of molar elements. Possible mold. 14. Claims characterized in that the coupling means for each pair of elongate mold sections is at one end of the mold and the pairs of elongate mold sections are electrically coupled at opposite ends of the mold. 14. The electrically heatable mold according to clause 13. 15. Claim 13, characterized in that each pair of elongated sections has a mold cavity for casting a strap on each of a number of pairs of lugs or rows of said elongated section elements. Electrically heatable mold as described. 16. The electrically heatable mold of claim 10, wherein the elongate portion and the coupling means define a continuous serpentine profile through which electrical current can be passed. 17. The electrically heatable mold of claim 16, wherein each of the outermost elongated portions is formed with a terminal to which the power source is coupled. 18. The electrically heatable mold of claim 8, wherein the body is made of stainless steel.